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Additive Manufacturing in volle ontwikkeling

Toon Roels, R&D Manager Industrial Services
Nieuwe ontwikkelingen
• Nieuwe Materialen
  • SL: High Impact materialen NeXT en Xtreme
  + Positionering tov ABS en PA
  • FDM: Ultem


• Spotlight op Tusk XC 2700 (SL)

• Hogere Proceskennis en Proces Controle
Stereolithografie: Xtreme and NeXt
• Xtreme is slagvast en heeft zeer evenwichtige
  eigenschappen, met daarenboven een uitstekende
  oppervlaktekwaliteit en scherpe contourdefinitie.
• Uitermate geschikt voor strakke designs.

• NeXT is slagvast, heeft een uitzonderlijk gunstige
  combinatie van stijfheid en impact sterkte en
  daarenboven een goede resistentie tegen water.
• Uitermate geschikt voor lange duur functionaliteit
Protogen Tusk      Xtreme NeXt
Tensile Modulus                    M Pa           2245   2765     1885   2430
Tensile Sterkte by breuk           M Pa             43  50.35       41    32.8
Tensile sterkte bij yield          M Pa
Elongatie bij breuk                %              12     15.5      18        9
Elongatie bij yield                %
Flex. Sterkte                      M Pa            68      68      61       70
Flex. Modulus                      M Pa          2060    2205    1795     2470
Heat deflection Temp. @ 0.46 Mpa   °C              54      48      62       56
Heat deflection Temp. @ 1.81 Mpa   °C              47      49      54       50

IZOD notched Impact                J/m             21      25     43.5    49.5
IZOD unnotched impact              kJ/m2           21      25       36      48
Water absorption                   %             0.68    0.35              0.4
High Impact Stereo vs ABS

                                                                                   spuitgiet
                                           Protogen Tusk      Xtreme NeXt        ABS AVG   ABS Range
Tensile Modulus                    M Pa           2245   2765     1885   2430      2370    1520-6100
Tensile Sterkte by breuk           M Pa             43  50.35       41    32.8      38       27-65
Tensile sterkte bij yield          M Pa
Elongatie bij breuk                %              12     15.5      18        9     26        2-110
Elongatie bij yield                %
Flex. Sterkte                      M Pa            68      68      61       70     70       40-111
Flex. Modulus                      M Pa          2060    2205    1795     2470    2380     1610-5900
Heat deflection Temp. @ 0.46 Mpa   °C              54      48      62       56     95       68-144
Heat deflection Temp. @ 1.81 Mpa   °C              47      49      54       50     88       65-220

IZOD notched Impact                J/m             21      25     43.5    49.5     237      10-640
IZOD unnotched impact              kJ/m2           21      25       36      48      39
Water absorption                   %             0.68    0.35              0.4



IZOD 1/ modulus*1000                               9        9      23       20
IZOD 2/modulus *1000                               9        9      19       20



    Xtreme en NeXt = een nieuwe generatie SL resins
FDM: Ultem 9085
• Ultem 9085= Polyetherimide
• High performance mbt. tot temperatuursresistentie en
  brandresistentie
• Product ‘met stamboom’
• Ultem >< PPSU: procesbaarheid en beschikbaarheid

                         General performance
FDM-Ultem 9085

• Maximale continue gebruikstemperatuur (ASTM D 794) ~170 º C

                         300

                         250
         Temperature ©




                         200

                         150

                         100

                          50

                          0
FDM- Ultem 9085

• Lage ‘Heat and smoke release’ - geschikt voor commerciële
  luchtvaart

• Inherente brandweerstand van Ultem geeft UL 94- V0
  performance


                 Materiaal   dikte
         FDM     PPSU        3.2 mm
                 Ultem       1 mm
         LS      PAFR        2 mm
         VC      VCPU FR     3 mm
Spotlight op een bekende:
                     Stereolithografie TuskXC2700

Capaciteit bij Materialise
• 4 Mammoths
• 2 SLA 250
• 2 SLA 7000


• Sleuteleigenschappen:
  • Transparantie (XC)
  • Lage wateropname→ Duurzaamheid
  • Medische goedkeuring (USP Class 6, Iso 10993)

  • Minpunt: lage T stabiliteit (hoewel: sterilisatie bij 138C mogelijk!)
TuskXC 2700: Lange termijn testing
Opslag van SL stukken in 5 condities gedurende 1 jaar:
•   Outdoor: dak Materialise (tijd, water, UV, ∆T, )
•   In light : achter glas in daglicht (tijd, UV)
•   In dark: donkere doos (tijd)
•   In dry: excicator (tijd)
•   In wet: vochtige emmer (tijd, water)


                                              Modulus

                       140
                       120
                                                                         outdoor
                       100
                                                                         in light
                       80
        % of Modulus




                                                                         in dark
                       60
                                                                         in dry
                       40
                                                                         in wet
                       20
                        0
                             referentie   1 maand   6 maand   12 maand
Additive Manufacturing:efficiëntere
                    processen, verhoogde automatisatie,
                    verhoogde kwaliteitscontrole
Stereolithografie en Laser sinteren
• Lagere laagdiktes (0.1 mm): verhoogde oppervlaktekwaliteit zonder
  manuele extra finishing
• Verhoogde Automatisatie bij genereren van Light supportstructuren SL:
  snellere datavoorbereiding, minder materiaal, snellere bouwtijden, minder
  aanhechtingspunten
• Verhoogde Online parametercontrole en -correctie op Mammoet
  machines
• Standaard QC van binnenkomende grondstoffen: SL harsen + 2-
  wekelijkse controle van de SL baden [viscositeit].
• Extra voorzorgen voor stukken bedoeld voor medische toepassingen
• Automatisatie van SLS process: poederlogistiek, stukbehandeling..


 →Hogere       & consistentere kwaliteit, Lagere prijs

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Additive manufacturing materialen in volle ontwikkeling toon roels

  • 1. Additive Manufacturing in volle ontwikkeling Toon Roels, R&D Manager Industrial Services
  • 2. Nieuwe ontwikkelingen • Nieuwe Materialen • SL: High Impact materialen NeXT en Xtreme + Positionering tov ABS en PA • FDM: Ultem • Spotlight op Tusk XC 2700 (SL) • Hogere Proceskennis en Proces Controle
  • 3. Stereolithografie: Xtreme and NeXt • Xtreme is slagvast en heeft zeer evenwichtige eigenschappen, met daarenboven een uitstekende oppervlaktekwaliteit en scherpe contourdefinitie. • Uitermate geschikt voor strakke designs. • NeXT is slagvast, heeft een uitzonderlijk gunstige combinatie van stijfheid en impact sterkte en daarenboven een goede resistentie tegen water. • Uitermate geschikt voor lange duur functionaliteit
  • 4. Protogen Tusk Xtreme NeXt Tensile Modulus M Pa 2245 2765 1885 2430 Tensile Sterkte by breuk M Pa 43 50.35 41 32.8 Tensile sterkte bij yield M Pa Elongatie bij breuk % 12 15.5 18 9 Elongatie bij yield % Flex. Sterkte M Pa 68 68 61 70 Flex. Modulus M Pa 2060 2205 1795 2470 Heat deflection Temp. @ 0.46 Mpa °C 54 48 62 56 Heat deflection Temp. @ 1.81 Mpa °C 47 49 54 50 IZOD notched Impact J/m 21 25 43.5 49.5 IZOD unnotched impact kJ/m2 21 25 36 48 Water absorption % 0.68 0.35 0.4
  • 5. High Impact Stereo vs ABS spuitgiet Protogen Tusk Xtreme NeXt ABS AVG ABS Range Tensile Modulus M Pa 2245 2765 1885 2430 2370 1520-6100 Tensile Sterkte by breuk M Pa 43 50.35 41 32.8 38 27-65 Tensile sterkte bij yield M Pa Elongatie bij breuk % 12 15.5 18 9 26 2-110 Elongatie bij yield % Flex. Sterkte M Pa 68 68 61 70 70 40-111 Flex. Modulus M Pa 2060 2205 1795 2470 2380 1610-5900 Heat deflection Temp. @ 0.46 Mpa °C 54 48 62 56 95 68-144 Heat deflection Temp. @ 1.81 Mpa °C 47 49 54 50 88 65-220 IZOD notched Impact J/m 21 25 43.5 49.5 237 10-640 IZOD unnotched impact kJ/m2 21 25 36 48 39 Water absorption % 0.68 0.35 0.4 IZOD 1/ modulus*1000 9 9 23 20 IZOD 2/modulus *1000 9 9 19 20 Xtreme en NeXt = een nieuwe generatie SL resins
  • 6. FDM: Ultem 9085 • Ultem 9085= Polyetherimide • High performance mbt. tot temperatuursresistentie en brandresistentie • Product ‘met stamboom’ • Ultem >< PPSU: procesbaarheid en beschikbaarheid General performance
  • 7. FDM-Ultem 9085 • Maximale continue gebruikstemperatuur (ASTM D 794) ~170 º C 300 250 Temperature © 200 150 100 50 0
  • 8. FDM- Ultem 9085 • Lage ‘Heat and smoke release’ - geschikt voor commerciële luchtvaart • Inherente brandweerstand van Ultem geeft UL 94- V0 performance Materiaal dikte FDM PPSU 3.2 mm Ultem 1 mm LS PAFR 2 mm VC VCPU FR 3 mm
  • 9. Spotlight op een bekende: Stereolithografie TuskXC2700 Capaciteit bij Materialise • 4 Mammoths • 2 SLA 250 • 2 SLA 7000 • Sleuteleigenschappen: • Transparantie (XC) • Lage wateropname→ Duurzaamheid • Medische goedkeuring (USP Class 6, Iso 10993) • Minpunt: lage T stabiliteit (hoewel: sterilisatie bij 138C mogelijk!)
  • 10. TuskXC 2700: Lange termijn testing Opslag van SL stukken in 5 condities gedurende 1 jaar: • Outdoor: dak Materialise (tijd, water, UV, ∆T, ) • In light : achter glas in daglicht (tijd, UV) • In dark: donkere doos (tijd) • In dry: excicator (tijd) • In wet: vochtige emmer (tijd, water) Modulus 140 120 outdoor 100 in light 80 % of Modulus in dark 60 in dry 40 in wet 20 0 referentie 1 maand 6 maand 12 maand
  • 11. Additive Manufacturing:efficiëntere processen, verhoogde automatisatie, verhoogde kwaliteitscontrole Stereolithografie en Laser sinteren • Lagere laagdiktes (0.1 mm): verhoogde oppervlaktekwaliteit zonder manuele extra finishing • Verhoogde Automatisatie bij genereren van Light supportstructuren SL: snellere datavoorbereiding, minder materiaal, snellere bouwtijden, minder aanhechtingspunten • Verhoogde Online parametercontrole en -correctie op Mammoet machines • Standaard QC van binnenkomende grondstoffen: SL harsen + 2- wekelijkse controle van de SL baden [viscositeit]. • Extra voorzorgen voor stukken bedoeld voor medische toepassingen • Automatisatie van SLS process: poederlogistiek, stukbehandeling.. →Hogere & consistentere kwaliteit, Lagere prijs